Brushless motor for a power tool

Abstract

A brushless motor includes a stator assembly including a generally-cylindrical stator body having a center bore, teeth extending from the stator body towards the center bore and defining slots in between, and windings wound around the teeth; and a rotor assembly rotatably received within the center bore and includes a rotor shaft and a generally-cylindrical rotor body. The motor further includes at least one rotor bearing mounted on the rotor shaft, and at least one bearing support member supporting the rotor bearing. The bearing support member includes a radial body forming a bearing pocket for receiving the rotor bearing therein, and axial post inserts received within the slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly.

The invention claimed is: 
     
       1. A brushless direct-current (DC) motor comprising:
 a stator assembly including a generally-cylindrical stator body having a center bore, a plurality of teeth extending from the stator body towards the center bore and defining a plurality of slots in between, and a plurality of windings wound around the plurality of teeth; 
 a rotor assembly rotatably received within the center bore of the stator assembly, the rotor assembly including a rotor shaft and a generally-cylindrical rotor body mounted on the rotor shaft; 
 at least one rotor bearing mounted on the rotor shaft; and 
 at least one bearing support member supporting the rotor bearing, the bearing support member including a radial body forming a bearing pocket at central portion thereon for receiving the rotor bearing therein, and a plurality of axial post inserts received within the plurality of slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly so as to maintain a circumferential gap between the rotor body and the plurality of stator teeth within the center bore of the stator assembly, 
 wherein the stator assembly comprises an end insulator arranged at an end surface of the stator body to insulate the plurality of stator teeth from the plurality of windings, the radial body of the bearing support member including a mating surface that mates with a mating surface of the end insulator to form a substantially uniform cylindrical body between the stator assembly and the bearing support member. 
 
     
     
       2. The motor of  claim 1 , wherein the at least one rotor earing comprises a rear bearing and a front bearing disposed at two sides of the rotor body, and the at least one bearing support member comprises a first bearing support member supporting the rear bearing and a second bearing support member supporting the front bearing. 
     
     
       3. The motor of  claim 1 , wherein the radial body of the bearing support member includes a mating surface that mates with an end portion of the stator assembly to form a substantially uniform cylindrical body between the stator assembly and the bearing support member. 
     
     
       4. The motor of  claim 1 , wherein the bearing support member supports a circuit board on which a plurality of positional sensors are mounted, the positional sensors being arranged to sense a magnetic position of the rotor assembly. 
     
     
       5. The motor of  claim 1 , wherein the bearing support member comprises a plurality of openings formed around the bearing pocket to allow passage of air through the bearing support member. 
     
     
       6. The motor of  claim 5 , further comprising a fan mounted on the rotor shaft facing the bearing support member, the fan generating airflow that passes through the stator assembly and the plurality of openings of the bearing support member. 
     
     
       7. The motor of  claim 1 , wherein at least one of the plurality of axial post inserts radially extends from a peripheral portion, arranged to engage the inner surface of the stator body, to an end portion, arranged at an open end of a corresponding slot engaging edges of two corresponding stator teeth. 
     
     
       8. The motor of  claim 7 , wherein the at least one axial post includes a generally rectangular cross-sectional profile. 
     
     
       9. The motor of  claim 1 , wherein the mating surfaces of the end insulator and the bearing support member include corresponding indentations and detents arranged to mate to properly align the bearing support member with respect to the stator assembly. 
     
     
       10. The motor of  claim 1 , wherein the rotor bearing is positioned along approximately a same radial plane as at least one of the end insulator or ends of the plurality of stator windings. 
     
     
       11. The motor of  claim 1 , wherein the bearing support member is configured to be fully slidingly received within the stator assembly. 
     
     
       12. A power tool comprising a housing, and a brushless direct-current (DC) motor disposed within the housing for driving an output spindle of the tool, the motor comprising:
 a stator assembly including a generally-cylindrical stator body having a center bore, a plurality of teeth extending from the stator body towards the center bore and defining a plurality of slots in between, and a plurality of windings wound around the plurality of teeth; 
 a rotor assembly rotatably received within the center bore of the stator assembly, the rotor assembly including a rotor shaft and a generally-cylindrical rotor body mounted on the rotor shaft; 
 at least one rotor bearing mounted on the rotor shaft; and 
 at least one bearing support member supporting the rotor bearing, the bearing support member including a radial body forming a bearing pocket at central portion thereon for receiving the rotor bearing therein, and a plurality of axial post inserts received within the plurality of slots of the stator assembly between adjacent sets of windings and engaging an inner surface of the stator body to support the rotor bearing with respect to the stator assembly along a center axis of the center bore of the stator assembly so as to maintain a circumferential gap between the rotor body and the plurality of stator teeth within the center bore of the stator assembly, 
 wherein the stator assembly comprises an end insulator arranged at an end surface of the stator body to insulate the plurality of stator teeth from the plurality of windings, the radial body of the bearing support member including a mating surface that mates with a mating surface of the end insulator to form a substantially uniform cylindrical body between the stator assembly and the bearing support member. 
 
     
     
       13. The power tool of  claim 12 , wherein an inner surface of the power tool housing comprises a plurality of piloting and retaining features configured to axially support the stator assembly and the at least one bearing support member with respect to one another.